Golf Car Operation Manual - Star EV

Operation Manual for Electric Golf Car and Lifted VehicleThanks for purchasing our electric golf car and lifted vehicle. This manual contains information forproper operation and maintenance of your vehicle. A thorough understanding of this manual willhelp you obtain maximum enjoyment from this vehicle. Keep this manual handy for futurereference.Important Information:Particularly important information is distinguished by the following notations:WARNING!Failure to follow Warning instructions could result in severe injury to the vehicle occupants,bystanders or persons inspecting or repairing the vehicle.CAUTION!Failure to follow Caution instructions could cause damage to the vehicle.Special Notice:Because the seat & backrest wrapping film may stick to the seat vinyl and cause seat vinylto fade or stain, remove the seat & backrest wrapping film when you start to use the vehicle.Even if you plan to store the vehicle for a long time, remove the seat & backrest wrappingfilm.1

Pictures for referenceStandard Golf Car2-passenger Golf Car4-passenger Golf Car6-passenger Golf CarUtility car based on 2-passenger golf car2 2, Jumper Seat2 2, Flip Seat2 seats, Cargo BoxUtility car based on 4-passenger golf car4 2, Jumper Seat4 2, Flip Seat4 seats, Cargo Box22 seats, Dumping CargoBox

Utility car based on 6-passenger golf car6 2, Jumper Seat6 2, Flip seat2 2 Lifted Car4 2 Lifted CarLifted Vehicle3

TABLE OF CONTENTS1. Overview. 52. Safe Operation Instructions . 63. Technical Data . 74. Controls . 155. Operation . 216. Maintenance . 227. Troubleshooting . 318. Lubrication . 339. Running-in of New Vehicle. 3310. Periodic Maintenance Charts . 3311. Storage. 3512. Wiring Diagram. 354

1. OverviewOur vehicle is environmentally friendly, and it can be used as people mover or utility car.WARNING!Always confirm whether there are restrictions in the area where you intend to use thevehicle. It is recommended that only people who possess a valid motor vehicle driver’slicense be allowed to operate golf cars.IMPORTANT LABELSSAFETY LABELRead carefully and understand the contents on the safety label.The label above is attached on the dash panel as below:Vehicle Information (Name Plate)The name plate is either on the back of the seat pod (Fig. 1) or below the dashboard (Fig. 2).5

Fig.1Fig.2Chassis number of the vehicle2. Safe Operation InstructionsOur vehicle is designed for simple operation; however, make sure you observe the following safeoperation instructions.6

BEFORE OPERATING: Read the user manual thoroughly before operating the vehicle. Allow only authorized people to operate the vehicle, and only from the driver’s side. Drive the vehicle only in areas where it is allowed by law or local regulations. DO NOT allow more people than is permitted on the vehicle. DO NOT overload the vehicle, otherwise the motor may be damaged. The vehicle may alsolose control and/or the driver and passengers will be in danger if overloaded. DO NOT operate the vehicle under the influence of alcohol or drugs. DO NOT climb any slope steeper than the vehicle’s climbing ability. DO NOT overtake other vehicles at crossroads, in blind spots or in any dangerous areas.WHILE OPERATING THE VEHICLE: Keep your entire body inside the vehicle, keep seated and hold on while the vehicle ismoving. Do not start the vehicle until all occupants are securely seated. Keep your hands on the steering wheel and your eyes on the path ahead. Always back up slowly, and watch carefully. Avoid starting or stopping suddenly. Avoid turning the steering wheel sharply at high speed. Always drive slowly up or down on a slope. Do not make any modification or addition which may affect the safety of the vehicle.3. Technical SpecificationsThe data below has been confirmed by an independent authority lab.7

Standard Golf Car2-PassengerITEMSVoltage (V)36VBattery6pcs x 6V4-Passenger48V6pcs x 8V36V8pcs x 6V6-Passenger48V48V6pcs x 6V8pcs x 6V8pcs x 6V6pcs x 860*1180*1940(L x W x H)Range(km/h)based onflat road at 55 55 80 100(AC system)25 for 3KW motor32 for 4KW DC motor32 for 4KW motor32 for 3KW AC motor 50 55 80 100(AC system) 70 90(AC system)25 for 3KW motor32 for 4KW DC motor32 for 4KW DC motor32 for 4KW motor32 for 3KW AC motor40 for 4KW AC motor40 for 5KW AC motor40 for 5KW AC motora speed of20km/hMaximumSpeed(km/h) for21Gear Ratio2140 for 5KW AC motorof 12.49:1Maximum27 for 3KW motorSpeed(km/h) for27 for 3KW motor2540 for 4KW motor7740 for 4KW DC motor40 for 4KW DC motor40 for 4KW DC motor25---Gear Ratioof 10.25:1MinimumTurningDiameter79(m)89911

lity20%25%25%Noise (dB)20%20%(3KW AC system)25% 70 70 4 425%20% 70MaximumBrakeDistance 4(V 20km/h)Utility car based on 2- passenger golf carITEMSVoltage (V)BatterySetup2 2 with Jumper seat2 2 with Flip Seat2 seats with Cargo Box36V48V36V48V36V48V6pcs x 6V8pcs x 6V6pcs x 6V8pcs x 6V6pcs x 6V8pcs x 180*1800(L x W x H)Range (km) based onflat road ata speed of 6070 100(ACsystem) 6070system)20km/h9 100(AC 5570 90(ACsystem)

MaximumSpeed(km/h) for32 for 4KW DC motor21Gear Ratio32 for 3KW AC motor32 for 4KW DC motor2132 for 3KW AC motor40 for 5KW AC motor32 for 4KW DC motor2140 for 5KW AC motor32 for 3KW AC motor40 for 5KW AC motorof city oftherearcargobed(kg)MaximumGradeabilityNoise (dB) 70 70 70 4 4 4MaximumBrakeDistance(V 20km/h)10

Utility car based on 4-passenger golf carITEMS4 2 with JumperSeat4 2 with Flip Seat4 seat with CargoBox2 seat with Cargo BoxVoltage (V)48V48V48V48V8pcs x 6V8pcs x 6V8pcs x 6V8pcs x 180*1890 BatterySetupDimensions(mm)(L x W x H)Range (km)based onflat road ata speed of70 80(ACsystem)70 80(ACsystem)70 80(ACsystem)70 80(ACsystem)20km/hMaximumSpeed(km/h) forGear Ratio32 for 4KW DC motor32 for 4KW DC motor32 for 4KW DC motor32 for 4KW DC motor40 for 4KW AC motor40 for 4KW AC motor40 for 4KW AC motor40 for 4KW AC motor9999480480480440----160280of city(Kg)LoadingCapacity of11

the rearcargo bedMaximumGradeabilityNoise (dB)20%20%20%20%70707070 4 4 4 4MaximumBrakeDistance(V 20km/h)Utility car based on 6-passenger golf carITEMS6 2 with Jumper Seat6 2 with Flip seatVoltage (V)48V48VBattery Setup8pcs x 6V8pcs x 6VN/AN/ARange (km) based on flat road at a speed of 20km/h 60 75(AC system) 60 75(AC system)Maximum Speed (km/h) for Gear Ratio of 12.49:125 for 5KW DC motor25 for 5KW DC motor32 for 5KW AC motor32 for 5KW AC motorMinimum Turning Diameter (m)1111Maximum Loading Capacity (Kg)640640Maximum Gradeability15%15%Noise (dB)7070Maximum Brake Distance (V 20km/h) 4 4Dimensions (mm)(L x W x H)Lifted Vehicle12

ItemsLifted Vehicle 2 2Lifted Vehicle 4 2Voltage(v)48V48VBattery Setup8pcx 6V8pcx 6VDimension(mm) (LxWxH)2950x1340x19903500x1340x2100Range(km) based on flat road at a speed of20km/h with 22’ flat teeth tire 70 55Maximum Speed (km/h) for Gear Ratio of12.49:132 for 4kw and 5.3kw motor35 for 4KW AC motor40 for 5KW AC motor32 for 4kw and 5.3kw motor35 for 4KW AC motor40 for 5KW AC motorMinimum Turing Diameter (m)69Maximum Loading Capacity (kg)300450Maximum Gradeability20%20%Noise (dB) 70 70Maximum Brake Distance (V 20km/h) 4 413

4. Controls1) Schematic Figure of Controls (Note: There are two types of dashboard on the vehicles. Thecup holder on the 08 & 09 Style Dashboard is on top of the instrument panel and the cup holderon the 06 Style Dashboard is below the instrument panel.)15

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2) Functions of ControlsPower KeyThe power key is used to switch on the electrical system of the vehicle.To engage the motor and start the vehicle, insert the key and turn it clockwise tothe ON position. At this time the 12V accessory system (headlights, turn signals,taillights, brake lights and horn) will be engaged too.To switch the power off, turn the key counterclockwise to the OFF position.CAUTION!When the key is in the ON position, it cannot be pulled out. DO NOT try toremove the key when it is in the ON position.Forward/Reverse SwitchThis is a three-position switch. The switch is used to shift the golf car intoforward or reverse. Press the switch up to move forward, down for reverse, or inthe middle for neutral.WARNING! This switch must be fully pressed into the proper position orthe electric system and motor will be damaged.NOTE: The buzzer will beep when the lower part of this switch is pressed towarning people around your vehicle.Accelerator PedalThe accelerator pedal is used to control speed while driving. Press itdown slowly to increase speed. The vehicle will speed up with thegradual depression of the accelerator pedal, eventually reaching topspeed when the pedal is completely pressed down. The vehicle slows18

down with the lifting of the pedal. When the pedal is fully lifted, the electric brake will engage andthe vehicle will come to a stop.Service Brake PedalThe service brake pedal is used for braking. The shape of the pedal of the mechanical brakesystem and the hydraulic brake system is different: refer to the figures below.NOTE: On the mechanical brake system, the service brake pedal is combined with the parkingbrake pedal.Parking Brake PedalThe parking brake pedal is used in braking for parking. The parking brake of the mechanical brakesystem is different from hydraulic brake system. The parking brake of mechanical brake system isengaged by foot as shown in above picture (refer to ‘Mechanical Brake’). The parking brake of thehydraulic brake system is engaged by hand as shown in the figure below. The parking brake shouldbe engaged into parking position whenever the vehicle is left unattended.How to engage and disengage the parking brakea. Mechanical brake systemTo engage the parking brake, press down the service brake pedal completely, then press downthe parking brake pedal until it locks.To disengage the parking brake, press down the service brake pedal until the parking brake pedalis unlocked.WARNING!19

The foot park brake will automatically release when the accelerator pedal is stepped down. Ifthe power key is in ON position, stepping down the accelerator pedal may suddenly causethe vehicle to move.b. Hydraulic brake systemTo engage the parking brake, pull up the hand brake lever to the end;To disengage the parking brake, pull the hand brake lever up completely and press the buttonon the top of the brake lever. Return the brake lever to the down position.WARNING!Always release the brake handle completely before driving the vehicle.WARNING!Do not press both the brake pedal and the accelerator together; this will damage the motor.Steering WheelThe steering wheel is used to control the driving direction. Avoid sudden and sharp turns.Battery Power MeterThere are 10 calibration marks on the meter. The meter will decline from the top tothe bottom as the battery discharges. When the battery is too low, the red indicatorlight will flash, reminding you to recharge the battery.20

NOTE: Refer to your Battery Charger’s Owners Manual for how to recharge the batteries.TOW/RUN SWITCH (available for Curtis 1266 and 1268 controller)Before operating the vehicle, make sure the TOW/RUN switch is on ‘RUN’ position.Make sure the TOW/RUN switch is on the “TOW’ position if towing the vehicle.The TOW/RUN switch is located under the seat on the passenger side either on the controller coveror just under the rear body as showed below picture.WARNING!Whenever the TOW/RUN switch is moved from the RUN position to the TOW position, moveit back to the RUN position, there is a delay of approximately 30 seconds before the vehiclewill run.TURN SIGNAL/HORN SWITCHThis switch is used to operate the turnsignals and horn.1) Lift up the handle lever to activate thehorn.2) Push the handle lever up to activate theright turn signal.3) Pull the handle lever down to activatethe left turn signal.Headlight SwitchPull out the button to switch on theheadlight.5. OperationSTARTING:a) With the Forward/Reverse switch on the Neutral position, turn the power key to ON position.CAUTION!The car will not run if the F/R switch is set to Forward or Reverse position before turning the key to21